Laminate Facing for Fiber Reinforced Materials and Composite Materials Formed Therefrom

ABSTRACT

The present invention provides a laminate material having a polyester film and a web of polyester fibers cohesively bonded directly thereto, such that portions of the fibers are bonded to the polyester film and portions of the fibers are free from the polyester film. The invention may also include a glass reinforced polymer layer formed on the laminated facer where the polymer of the glass reinforced polymer layer is commingled with the nonwoven of the laminated facer. The laminate may further include a second polymer layer having a thickness joined to the fiber layer and/or a layer of hot melt adhesive applied to the polyester fibers. Also presented is a composite material having a polyester film, a layer of polyester fibers bonded to the second polymer layer; a second polymer layer joined to the polyester film; and a glass reinforced polymer layer formed on the laminated facer, where the polymer of the class reinforced polymer layer is commingled with the nonwoven of the laminated facer.

PRIORITY

This Application is a Continuation-In-Part of U.S. application Ser. No.13/851,662, filed Mar. 27, 2013, which is a Utility Application basedupon Provisional Application Ser. No. 61/616,863, filed Mar. 28, 20012,entitled, “Laminate Facing for Fiber Reinforced Materials and CompositeMaterials Formed Therefrom” with inventor: Thomas Miller. All aspects ofProvisional Application Ser. No. 61/616,863 are hereby incorporated byreference.

BACKGROUND

Polypropylene films are often used as surface materials for laminatesand composite materials, are known for use in lining tucks, refrigeratedshipping containers and other industrial and construction materials.Typically, a film such as polypropylene or other substrate such as PETis bonded to a nonwoven. The polypropylene face layer is not a suitablydurable, temperature resistant or chemically inert surface. Thepolypropylene facers are generally not suitable for use with a thermosetcomposite due to adherence issues and temperature resistance.Polypropylene is typically porous and difficult to clean and istherefore generally not suitable for use for a number of applications.The polypropylene laminate is formed with a film of polypropylene, towhich a layer of polypropylene is extruded, and the extrudedpolypropylene adheres to the film and the nonwoven material. Thethree-step process increases material costs, processing expense andmaterial waste.

SUMMARY

In accordance with embodiments, the present invention relates tolaminate facings for fiber reinforced or composite materials andmaterials formed therefrom. The laminate facings are generally formed ofa polyester film layer bonded directly to a nonwoven fibrous layer. Thefacings are cohesively bonded to a nonwoven, typically roll beaded,point bonded or bonded by any other suitable method, including coformingof the fiber layer on the film or the film layer on the fibrous layerdirectly such that the fibers and the polyester film facing areintegrally joined without the use of a subsequently applied layer ofadhesive or other polymer. The composite materials may be formed byapplying the laminate to a surface and depositing fiber reinforced resinto the laminate or applying the laminate to the surface of afiber-reinforced resin during manufacture. The laminate provides arugged outer layer for composite materials and may reduce volatileorganic compound emissions by replacing a gel coat fryer. The laminatemay also include a metalized layer such as aluminum, molybdenum,tantalum, titanium, nickel, and tungsten. The metalized layer improvesthermal properties by forming a radiant barrier and also improvesopacity of the facing and provides an aesthetically pleasing appearance.

In accordance with embodiments of the present invention the films may beproduced by conventional forming such as casting, blowing, and extrusionor coextrusion processes. The extruded films are created with a singlebase layer made from an extrudable thermoplastic polymer and may includeone or more exterior layers. One suitable exterior layer includes arelatively low melting point heat sealable polymer to improve thebonding of the film to the fibrous layer. The bonding material of thefilm is a heat sealable polymer layer designed to melt bond to thepolymer of the fiber layer. In an alternate embodiment of the presentinvention, a metalized or ink layer may be deposited on one surface orboth surfaces of the laminate.

Bicomponent fibers may be incorporated into nonwovens by severalprocesses. The spunbond process may be adapted to create bicomponentfibers of a sheath/core type and lay these fibers continuously onto aconveyor wherein they can be consolidated into a nonwoven web and woundinto a roll. Consolidation may be provided by heated rolls either of apattern including point bonding, or more preferably in this case ofsmooth surfaces to provide more uniform bonding over the entire surfaceof the nonwoven web of continuous fibers.

Alternatively, Bicomponent fibers may be produced and then cut andcrimped into staple fibers. Staple fibers may then be blended and mixedwith other fiber types and dimensions, then carded and run onto aconveyor wherein they can be consolidated into a nonwoven web and woundinto a roll. Consolidation may be provided by heated rolls either of apattern including point bonding, or more preferably in this case ofsmooth surfaces to provide more uniform bonding over the entire surfaceof the nonwoven web of continuous fibers.

There are several advantages for using staples fiber blends forprocessing, performance, and cost. A notable difference between the twodescribed methods is that a nonwoven web formed of continuous fibers isformed of layers of superimposed fibers, whereas a nonwoven web ofstaple fibers has substantial interleaving of the fibers such that eachfiber may be present in part on both top and bottom surfaces. While aspunbond line adapted for the production of bicomponent fibers may onlyprovide a singular specification of fiber for a given layer of thenonwoven, a production line using staple fibers may blend several typesof fibers throughout the nonwoven web. Staple fiber blending is commonand easily controlled, and the benefits of blending can provideenhancements of performance and cost. In addition, a production lineusing staple fibers may be more easily controlled for speed to providegreater flexibility of the weight of nonwoven achieved as well as theintroduction of films into the process.

In accordance with an alternate embodiment of the present invention ispresented having a composite material of a laminated facer having apolyester film with a thickness of 0.5-5 mil and a layer of polyesterfibers having a density of 17-100 GSM bonded thereto; and a glassreinforced polymer layer formed on the laminated facer where the polymerof the glass reinforced polymer layer is commingled with the nonwoven ofthe laminated facer.

In accordance with an alternate embodiment of the present invention ispresented having a laminate material having a polyester film having athickness of 0.5-2 mil, a layer of polyester fibers having a density of17-70 GSM bonded to the polyester film and a second polymer layer havinga thickness of 0.5-5 mil joined to the polyester ⁻fibers.

In accordance with an alternate embodiment of the present invention ispresented having a composite material having a polyester film having athickness of 0.5-2 mil, a layer of polyester fibers having a density of17-70 GSM bonded to the film, a second polymer layer having a thicknessof 0.5-5.5 mil joined to the polyester fibers and a glass reinforcedpolymer layer formed on the laminated facer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and the many embodimentsthereof will be readily obtained as the same becomes better understoodby reference to the following detailed description when considered inconnection with the accompanying drawings, wherein:

FIG. 1A illustrates a plan view of the formation of the laminatematerial in accordance with one aspect of the present invention.

FIG. 1B illustrates a plan view of the formation of the laminatematerial in accordance with another aspect of the present invention.

FIG. 2A illustrates a plan view of the metallization of the laminatematerial in accordance with one aspect of the present invention.

FIG. 2B illustrates a plan view of the metallization of the laminatematerial in accordance with one aspect of the present invention.

FIG. 3 illustrates a plan view of the composite material of the presentinvention with a laminate layer and a non-woven included.

FIG. 4A is a schematic top view of the laminate of the presentinvention.

FIG. 4B is a schematic cross-sectional view of the laminate of thepresent invention.

FIG. 5 is a schematic cross-sectional view of another laminate of thepresent invention including an adhesive layer or filler layer applied tothe nonwoven layer.

FIG. 6A is a cross-sectional schematic view of a preform (prior toconsolidation) of a laminate in accordance with one aspect of thepresent invention with a single fiber of a monocomponent fiber web on alaminated polymer film.

FIG. 6B is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a single fiber of amonocomponent fiber web consolidated with a laminated polymer film.

FIG. 6C is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a single fiber of amonocomponent fiber web consolidated with a laminated polymer film witha film applied to the fiber side of the laminate.

FIG. 6D is a cross-sectional schematic view of a preform (prior toconsolidation) of a laminate in accordance with one aspect of thepresent invention with a single fiber of a bicomponent fiber web on alaminated polymer film.

FIG. 6E is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a single fiber of abicomponent fiber web consolidated with a laminated polymer film suchthat the polymer of the polymer layer and the polymer of the bicomponentfiber are merged.

FIG. 6F is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a single fiber of abicomponent fiber web consolidated with a laminated polymer film with afilm applied to the fiber side of the laminate.

FIG. 7A is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a fiber web of mixedmonocomponent and bicomponent fiber web consolidated with a laminatedpolymer.

FIG. 7B is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a fiber web of mixedmonocomponent and bicomponent fiber web consolidated with a laminatedpolymer film with a film applied to the fiber side of the laminate.

FIG. 7C is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a fiber of a mixedmonocomponent and bicomponent fiber web consolidated with a laminatedpolymer film and having a subsequent polymer layer deposited over thefiber web.

FIG. 8A is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a fiber of a mixedmonocomponent and bicomponent fiber web consolidated with a laminatedpolymer film and having a subsequent polymer layer deposited over thefiber web and an additional layer deposited on the laminated polymerfilm.

FIG. 8B is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a fiber of a mixedmonocomponent and bicomponent fiber web consolidated with a laminatedpolymer film and having a subsequent polymer layer deposited over thefiber web and an additional layer deposited on the laminated polymerfilm and a building material layer, such as stucco applied over thelaminate.

FIG. 8C is a cross-sectional schematic view of a laminate in accordancewith one aspect of the present invention with a fiber of a mixedmonocomponent and bicomponent fiber web consolidated with a laminatedpolymer film and having a number of subsequent polymer layers depositedover the fiber web.

DETAILED DESCRIPTION

The present invention will now be described with occasional reference tothe specific embodiments of the invention. This invention may, however,be embodied in different forms and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments are providedso that this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The terminology used in thedescription of the invention herein is for describing particularembodiments only and is not intended to be limiting of the invention. Asused in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities ofingredients, properties such as molecular weight, reaction, conditions,and so forth as used in the specification and claims are to beunderstood as being modified in all instances by the term “about”.Accordingly, unless otherwise indicated, the numerical properties setforth in the specification and claims are approximations that may varydepending on the desired properties sought to be obtained in embodimentsof the present invention. Notwithstanding that the numerical ranges andparameters setting forth the broad scope of the invention areapproximations, the numerical values set forth in the specific examplesare reported as precisely as possible. Any numerical values, however,inherently contain certain errors necessarily resulting from error foundin their respective measurements.

Fibrous nonwoven webs provide an improved bonding surface between apolymer film layer and a fiber reinforced polymer composite material.Preferred nonwoven webs are formed with staple fibers that are cardedand then may be bonded with a heat and/or pressure process such as hotcalendering, including area bonding, point bonding and embossing; beltcalendaring; through-air thermal bonding; ultrasonic bonding; orradiant-heat bonding. The web may be additionally, or alternatively,chemically bonded to improve mechanical properties. Many bonding methodsare available including powder bonding using a powdered adhesive addedto the web and then typically heated. In a preferred embodiment, pointor pattern bonding using heated calender rolls or ultrasonic bondingequipment is used to bond the fibers together. Point bonding providesfor a secure bonding of the nonwoven to the polyester film while leavingunbonded fibers available to commingle with the composite laminate orother coating resin. Roll bonding may be used to bond the web across itsentire surface. Bicomponent or multicomponent staple fibers may be usedin the process as well and generally, a blend of single component fibersand bicomponent fibers is preferred.

As seen in FIG. 1A, roll 16 of polymer film 18 and roll 12 of nonwoven14 is laminated by calender rolls 20, 22. The resulting laminate 24 istaken up roll 26. The polymer film is preferably 0.5-5.0 mil thick. Apolyester film such as polyethylene terephthalate sold under the tradenames Mylar, Skyrol, Melinex or Hostaphan may be used. Generally, thebonding temperature is 130-180° C. Preferably, a temperature of about140-170° C. is to be used in the bonding process. The fibers and thepolyester film facing are cohesively bound, that is, integrally joinedwithout the use of an intermediate layer of adhesive or other polymer.As shown in TABLE 1, a layer of polypropylene or another polymer or alower grade of polyester may be applied to the nonwoven. The use oflower coat polymers may substantially decrease the overall cost of thematerial without substantially altering the properties.

In FIG. 1B, the polymer film 18 in taken off roll and fed into nonwovenfiber deposition device 10 such that nonwoven 12 is applied to film 18and the nonwoven 12 and film 18 are laminated by calender rolls 20, 22.The resulting laminate 24 is taken up roll 26. FIG. 2A shows theprinting process in which laminate 24 is unrolled from roll 26 fedthrough a printing device to form a printed laminate 30 that is rolledonto take-up roll 32.

FIG. 2B shows the vapor deposition of metallic compounds in whichlaminate 24 is unrolled from roll 26 fed through a deposition device toform a metalized laminate 30, which is rolled onto take-up roll 32.Various deposition methods may he used including chemical vapordeposition, physical vapor deposition. Metals such as molybdenum,tantalum, titanium, nickel, and tungsten are generally applied by CVD.For the deposition of aluminum, CVD may be used with tri-isobutylaluminum, tri ethyl/methyl aluminum, or dimethyl aluminum hydrideprecursors or a physical deposition process may be used. Electrostaticspray assisted vapor deposition, plasma and electron-beam deposition mayalso be used. The metalized layer may be formed on either the polyesterfilm layer or the non-woven layer. It may also be advantageous todeposit a metallic coating on both sides of the laminate for improvedcoverage, durability, and aesthetics.

FIG. 3 shows a composite material 38 including a resin layer 36including fibers 40 and laminate 24. Laminate 24 induces polymer filmlayer 18 bonded to nonwoven 14. The resin 36 infuses into the fibers ofthe nonwoven layer to provide an integrated mechanical bond. Themechanical bond formed between the resin 36 and the fibers of nonwovenlayer 14 is substantially stronger than the chemical bond formed betweenthe resin and the surface of the polymer layer 18. Any resin infusiontechnology, such as liquid molding, resin transfer molding, vacuumassisted resin transfer molding, vacuum infusion processing andcomposite infusion molding processing as well as vacuum bag molding,open molding, press molding, may be used to form composite member 38.Other processes such as hot calendering of the laminate onto the resinlayer or use of the laminate as a surface film in pulltrusion may beused to form composite member 38.

FIG. 4A and FIG. 4B show the point bonded laminate of the presentinvention including a non-woven layer 14 positioned on poly film 18. Thepoint bonding sites 14′ are formed by rollers 20, 22 (as shown in FIG. 1). The point bond sites 14′ are substantially compressed such that thepolymer of the fiber in the nonwoven 14 is integrally joined with thepolymer of the film 18. One or both of the rollers 20, 22 may be heatedto melt the fibers to bond with film 14.

FIG. 5 shows another embodiment of the laminate 44 including a polymerfilm 18, a fibrous layer 24 and a polymer layer 46 applied to thenonwoven layer with bonding sites 14′ bonding film 18 to fibers 24. Thelaminate may be formed as described above to form a laminate materialhaving a polyester film having a thickness of 0.5-2 mil; a layer ofpolyester fibers having a density of 17-70 GSM bonded polyester film anda polymer layer of polyethylene, polyvinylidene fluoride, poly(methylmethacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinylfluoride, polyester, polyurethane, polypropylene, polyethyleneterephthalate, polyurea, polyvinyl chloride, EMA, or EVA. A secondpolymer 46 may also be a hot melt adhesive applied to the fibers. Thehotmelt adhesives may be any known including Ethylene-vinyl acetate(EVA) copolymers, Ethylene-acrylate copolymers such as ethylene n-butylacrylate (EnBA), ethylene-acrylic acid (EAA) and ethylene-ethyl acetate(EEA), Polyolefins such as low or high density polyethylene, atacticpolypropylene, polybutene-1, and oxidized polyethylene, Polybutene-1 andits copolymers, Amorphous polyolefin polymers, Polyamides andpolyesters, Polyurethanes, Thermoplastic polyurethane, reactiveurethanes, Styrene block copolymers such as Styrene-butadiene-styrenesuch as Styrene-isoprene-styrene, Styrene-ethylene/butylene-styrene, andStyrene-ethylene/propylene. Other hotmelt adhesives may includePolycaprolactone Polycarbonates, Fluoropolymers, Silicone rubbers,thermoplastic elastomers and Polypyrrole may also be used.

FIG. 6A is a cross-sectional schematic view of a preform of a laminateformed with a film having base layer 110 and heat sealable layer 112with a single monocomponent fiber 114 of a monocomponent fiber web. Atthe junction of fiber 114 and layer 112 recesses 114′, 114″ are formed.

FIG. 6B is a cross-sectional schematic view of a laminate formed withlayers, 110, 112 with a single monocomponent fiber 114 of amonocomponent fiber web consolidated thereto. Heat sealable polymerlayer 112 is formed of a lower melting point material than fiber thatwhen the fiber 114 and layer 112 are consolidated by heat and pressure,heat sealable layer 112 Recesses 114′, 114″ formed at the junction offiber 114 and layer 112, remain after consolidation of the fiber 114 andlayer 112.

FIG. 6C is a cross-sectional schematic view of a laminate formed withlayers, 110, 112 with a single monocomponent fiber 114 of amonocomponent fiber web consolidated thereto. Preferably, polymer layer112 and fiber 114 are formed of a compatible or miscible material suchthat when the fiber 114 and layer 112 are consolidated by heat andpressure there is no substantial variation in the material. Anadditional layer 122 is shown over layer 112 and fiber 114. Layer 122maybe any suitable material, such as an additional polymer layer or ametallization layer a printing ink, or successive combination thereof.Junctions of fiber 114 and layer 112 form along the length of fiber 114such that fiber 114 is anchored in areas and free from layer 112 inareas. The unanchored areas of fiber 114 may be completely surrounded bysubsequent polymer layers to form a strong mechanical bond.

FIG. 6D is a cross-sectional schematic view of a preform of a laminateformed with layers, 110, 112 with a single multicomponent fiber 116 of afiber web. Multicomponent fiber 116 may include core 118 and clad layer120 or may be and other suitable multicomponent fiber structure. At thejunction of fiber 116 and layer 112 recesses 116′, 116″ are formed. Aswith fiber 114, junctions of fiber 116 and layer 112 form along thelength of fiber 116 such that fiber 116 is anchored in areas and freefrom layer 112 in areas. The unanchored areas of fiber 116 may becompletely surrounded by subsequent polymer layers to form a strongmechanical bond.

FIG. 6E is a cross-sectional schematic view of a laminate formed with afilm having layers, 110, 112 with a single multicomponent fiber 116 of afiler web consolidated thereto. Preferably, polymer layer 112 and sheathlayer 120 are formed of a compatible or miscible material such that whenthe fiber sheath 120 and layer 112 are consolidated by heat and pressurethere is no substantial variation in the material. Typically, with acore clad fiber the clad layer 120 would be compatible with layer 112.Recesses 116′, 116″ formed at the junction of fiber 116 and layer 112,remain after consolidation of the fiber 116 and layer 112.

FIG. 6F is a cross-sectional schematic view of a laminate formed withlayers, 110, 112 with a single multicomponent fiber 114 of a fiber webconsolidated thereto. An additional layer 122 is shown over layer 112and fiber 114. Layer 122 maybe any suitable material, such as anadditional polymer layer, a metallization layer, printing ink, or acombination thereof. Recesses 116′, 116″ formed at the junction of fiber116 and layer 112, remain after consolidation of the fiber 116 and layer112 and the subsequent deposition of layer 122.

FIG. 7A is a cross-sectional schematic view of a preform of a laminateformed with film layers, 110, 112 with monocomponent fibers 114, 130 andmulticomponent fiber 116, shown with core 118 and clad layer 120 or maybe another suitable multicomponent fiber structure. At the junction offiber 114 and layer 112 recesses 114′, 114″ are formed and at thejunction of fiber 116 and layer 112 recesses 116′, 116″ are formed.Fibers 130 and 114 are generally the same blended and carded fibersdiameter as fed into the web processing steps.

FIG. 7B is a cross-sectional schematic view of a laminate formed withlayers, 110, 112 with a single monocomponent fiber 114 and a singlemulticomponent fiber 120 of a mixed fiber web consolidated thereto.Preferably, polymer layer 112, fiber 114 and a portion of fiber 116 areformed of a compatible or miscible material such that when the fibers114, 116 and layer 112 are consolidated by heat and pressure there is nosubstantial variation in the material. Typically, with a core clad fiberthe clad layer 123 would be compatible with layer 112. Recesses 114′,114″ formed at the junction of fiber 114 and layer 112 and recesses116′, 116″ formed at the junction of fiber 116 and layer 112 and remainafter consolidation of the fiber 114 and layer 112. An additional layer122 is shown over layer 112 and fiber 114. Layer 122 maybe any suitablematerial, such as an additional polymer layer or a metallization layer.

FIG. 7C is a cross-sectional schematic view of a preform of a laminateformed with layers, 110, 112 with monocomponent fiber 114, andmulticomponent fibers 116, 132, shown with core 118 and clad layer 120and core 136 and clad layer 134 or may be and other suitablemulticomponent fiber structure. At the junction of fiber 114, and layer112 recesses 114′, 114″ are formed and at the junction of fiber 116 andlayer 112 recesses 116′, 116″ are formed. Additional polymer layer 138is applied to fibers 114, 116, 132 such that a chemical bond is formedtherebetween and a mechanical bond is formed when polymer layer 138surrounds a portion of the fiber at recesses 114′ and 116′ as well asthe circumference of fibers 114, 116 where the fibers are not joined tolayer 112 or to fiber 132.

FIG. 8A is a cross-sectional schematic view of a composite materialincluding a laminate formed with layers, 110, 112, 158 with a singlemonocomponent fiber 114 and a single multicomponent fiber 120 of a mixedfiber web consolidated thereto. Alternatively, layer 158 may be appliedin a post-processing step to include. Preferably, polymer layer 112 anda clad layer 118 of fiber 116 are formed of a compatible or misciblematerial such that when the fibers 116 and layer 112 are consolidated byheat and pressure there is no substantial variation in the material.Typically, with a core clad fiber the layer 120 would be compatible withlayer 112. Recesses 114′, 114″ formed at the junction of fiber 114 and,layer 112 and recesses 116′, 116″ formed at the junction of fiber 116and layer 112 and remain after consolidation of the fiber 114 and layer112. An additional layer 122 is shown over layer 112 and fiber 114.Layer 122 maybe any suitable material, such as an additional polymerlayer or a metallization layer. Additional layer 138 such as a fiberreinforced composite material is applied to fibers 114, 116, 132 suchthat a mechanical bond is formed with the recesses 114′ and 116 andaround the circumference of unbonded regions of fiber 114, 116.

FIG. 8B is a cross-sectional schematic view of a laminate formed withlayers, 110, 112 and additional layer 160 with a single monocomponentfiber 114 and a single multicomponent fiber 120 of a mixed fiber webconsolidated thereto. Preferably, polymer layer 112, fiber 114 and aportion of fiber 116 are formed of a compatible or miscible materialsuch that when the fibers 114, 116 and layer 112 are consolidated byheat and pressure there is no substantial variation in the material.Typically, with a core clad fiber the clad layer 120 would be compatiblewith layer 112. Recesses 114′, 114″ formed at the junction of fiber 114and layer 112 and recesses 116′, 116″ formed at the junction of fiber116 and layer 112 and remain after consolidation of the fiber 114 andlayer 112. An additional layer 122 is shown over layer 112 and fiber114. Layer 122 maybe any suitable material, such as an additionalpolymer layer or a metallization layer. Additional polymer layer 138,such as a fiber reinforced polymer, is applied to fibers 114, 116, 132such that a chemical bond is formed therebetween and a mechanical bondis formed with the recesses 114′ and 116′ as well as the circumferenceof fibers 114, 116 where the fibers are not joined to layer 112.Exterior layer 160 such as a building material, for example, a foamedpolymer, and adhesive layer or a cementitious stucco may be appliedafter the laminate is mounted to a wall.

FIG. 8C is a cross-sectional schematic view of a preform of a laminateformed with layers, 110, 112 with monocomponent fiber 114, andmulticomponent fitters 116, 132, shown with core 118 and clad layer 120and core 136 and clad layer 134 or may be and other suitablemulticomponent fiber structure. Additional layers fiber of reinforcedcomposite material may be applied such that the polymer matrix of thecomposite saturates the fiber layer of the Film/Fiber Laminate 150, 152,154, 156 may be added to form a composite such as a four-ply structurewith fiber alignment of 0/90/90/0.

The laminate and composite material of the present invention is suitablefor use in any composite structures including truck and trailer liners,refrigerated shipping container liners, ladder rails, tool handles,window lineals, structural materials, wall panels for use in foodpreparation, health care or sanitary applications, wall panels forrecreational vehicles, polls and cross arms, pilings or otherinfrastructure applications, and signage; or electronic materials suchas substrates for electronic boards, laminates for solar panels,integrated circuits, industrial switching, capacitors, and electricalboards; and insulation such as foam facers, glass or mineral woolfacers, and radiant heat barriers.

EXAMPLES

Generally, polyester layers are combined with nonwoven layers a widerange of potential laminates is shown in TABLE 1. The polyester filmused in each trial ranged from 48 to 200 gauge thickness. The spunbondnonwoven ranges from 34.50 GSM. The PP/Glass composite fiber is 50%glass fibers and 50% polypropylene fibers.

The examples cited in Table 1 include spunbond continuous monocomponentfibers, (examples IA, 1B, 2), spunbond continuous bicomponent fibers,(examples 3, 4), and staple (discontinuous) bicomponent fibers blendedwith monocomponent fibers (examples 5, 6, 7, 8).

Examples 1A and 1B were produced at the same time, and example 1B hadthe additional process of application of a coating of Polypropyleneapplied to the fiber side. They were each then laminated to a similarcomposite of Fiberglass and Polypropylene. The tests demonstrated animprovement is shear performance with the coating of example 1B.

Example 2 was produced analogous to examples 1 and then additionalprocessed by ultrasonic bonding. Subsequent tests confirmed an increaseof peel strength.

Examples 3 and 4 demonstrated improved peel strength when using thecontinuous bicomponent fibers.

Examples 5, 6, 7, 8 demonstrated further improved peel strength whenusing the staple (discontinuous) bicomponent fibers blended withmonocomponent fibers, and substantially higher shear strength. This wasconfirmed for a range of film thickness and fiber weights.

In Examples, 3-8 bicomponent fibers having a 50/50 ratio of core tosheath are used. Any suitable multicomponent fiber may be used providedthat a relatively low melting point polymer is available at the surfaceof the fiber for bonding.

The polypropylene layer of example 1B is applied at 108 GSM (˜3.5 milsthick). The use of a second polymer layer improves the strength of thefinal bond to the composite board, improving the shear strength from 175PSI to 235 PSI. The use of sheath/core fibers substantially increasedthe peel and shear strengths.

TABLE 1 Polymer Film and Polymer Fiber Surface Laminates Applied toFiberglass/Polypropylene Composite Material Example Number 1A 1B 2 3 4 56 7 8 Film Type Extrusion with Biaxial Orientation Base Polymer PET PETPET PET PET PET PET PET PET UV Additives Yes Yes Yes Yes Yes No Yes YesNo Heat Sealable Layer PET PET PET PET PET PET PET PET PET CoPolymerCoPolymer CoPolymer CoPolymer CoPolymer CoPolymer CoPolymer CoPolymerCoPolymer Adhesion Coating No No No No No Yes No No No Thickness Gauge80 80 80 80 80 48 80 100 200 Fiber Layer Fiber Type ContinuousContinuous Continuous Continuous Continuous Staple Staple Staple StapleFiber Polymer 100% PET 100% PET 100% PET 100% PET 10% PET 10% PET 10%PET 10% PET 10% PET BiCo BiCo 20% BiCo 20% BiCo 20% BiCo 20% BiCo 20%PET PET PET PET PET Bonding Type Pointbond Pointbond Ulrasonic FlatbondFlatbond Flatbond Flatbond Flatbond Flatbond Weight, gsm 34 34 34 17 3420 20 20 50 PP Coating gsm 108 Composite Type Fiberglass/ Fiberglass/Fiberglass/ Fiberglass/ Fiberglass/ Fiberglass/ Fiberglass/ Fiberglass/Fiberglass/ pp pp pp pp pp pp pp pp pp Weight Percent 65/35 65/35 65/3565/35 65/35 65/35 63/35 65/35 65/35/ Ply Thickness, mils 15 15 15 15 1515 15 15 15 Ply Orientation 0/90/90/0 0/90/90/0 0/90/90/0 0/90/90/00/90/90/0 0/90/90/0 0/90/90/0 0/90/90/0 0/90/90/0 Total Thk, mils 60 6060 60 60 60 60 60 60 Test Data Peel Strength, 28 28 60 37 62 71 77 83 71N/50 mm Lap Shear Strength, 175 215 351 351 391 421 psi

The present invention should not be considered limited to the specificexamples described herein, but rather should be understood to cover allaspects of the invention. Various modifications, equivalent processes,as well as numerous structures and devices to which the presentinvention may be applicable will be readily apparent to those of skillin the art. Those skilled in the art will understand that variouschanges may be made without departing from the scope of the invention,which is not to be considered limited to what is described in thespecification.

What is claimed is:
 1. A laminate material comprising: a base layer of apolymer film a heat sealable polymer film having a thickness of 0.5-5mil, and a bonded fiber web having a density of 17-100 GSM and includingpolymer fibers cohesively bonded directly thereto, such that portions ofthe fibers are bonded to the polymer film and portions of the fibers arefree from the polymer film.
 2. The laminate material of claim 1, whereinthe polymer tint is a polyester film.
 3. The laminate material of claim1, wherein the polymer film is a polyethylene terephthalate film.
 4. Thelaminate material of claim 1, wherein the polymer fibers comprisepolyester.
 5. The laminate material of claim 1, wherein the polymerpolyethylene terephthalate.
 6. The laminate material of claim 1, whereinthe polymer is selected from the group consisting of polyethylene,polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate,acrylonitrile butadiene styrene, polyvinyl fluoride, polyester,polyurethane, polypropylene, polyethylene terephthalate, polyurea,polyvinyl chloride, EMA, or EVA.
 7. The laminate material of claim 1,wherein the polymer fibers are selected from the group consisting ofpolyethylene, polyvinylidene fluoride, poly(methyl methacrylate),polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride,polyester, polyurethane, polypropylene, polyethylene terephthalate,polyurea, polyvinyl chloride, EMA, or EVA.
 8. The laminate material ofclaim 1, wherein the base layer has a softening point T1 and the and theheat sealable layer has a softening point T2, such that T2<T1.
 9. Thelaminate material of claim 1, wherein the monocomponent fibers have asoftening point T3 such that T3>T2.
 10. The laminate material of claim 1wherein a polymer in the multicomponent fibers has a softening point T4such that T4<T1.
 11. The laminate of claim 1, wherein the bonded fiberweb includes a mixture of monocomponent fibers and multicomponentfibers.
 12. The laminate of claim 1, wherein the bonded fiber has adensity of 20-50 GSM and the web includes staple fibers.
 13. Thelaminate of claim 1, wherein the bonded fiber has a density of 20-50 GSMand the web includes continuous fibers.
 14. The laminate of claim 1,wherein the cohesive bond is selected from the group consisting of meltbonding, point bonding and roll bonding.
 15. The laminate of claim 1,further comprising: a layer selected from the group consisting of ametal layer, an ink layer, a polymer layer deposited on at least onesurface of the laminate.
 16. The laminate of claim 1, furthercomprising: a layer applied to the base layer opposite heat sealablelayer, the layer se -polymers (polyethylene, low melt PET, acrylic,polyurethane, ink, polyester, polypropylene, polyethylene terephthalate,polyurea or polyvinyl chloride) or a vapor deposited metals.
 17. Thelaminate of claim 1, wherein the polyester film has a thickness of0.5-3.0 MIL.
 18. The laminate of claim 1, wherein the polyester film hasa thickness of 0.5-3.0 MIL and the nonwoven has a density of 30-65GSM³¹.
 19. The laminate of claim 1, wherein the polyester film has athickness of 0.5-1.5 MIL and the nonwoven has a density of 17-35 GSM.20. The laminate of claim 1, further comprising: an extrusion coatedpolymer layer having a thickness of 30-260 GSM joined to the nonwoven.21. The laminate of claim 20, wherein the extrusion coated polymer layeris selected from the group consisting of polyethylene, polyester,polyurethane, polypropylene, polyethylene terephthalate, polyurea,polyvinyl chloride, EMA, or EVA.
 22. A composite material, comprising: alaminated facer having a polymer film haying a thickness of 0.5-5 miland a bonded fiber web having a density of 17-100 GSM fibers beingcohesively bonded directly to the polymer film, such that portions ofthe fibers are bonded to the polymer film and portions of the fibers arefree from the polymer film; and a fiber reinforced polymer layer formedon die laminated facer; whereby, the polymer of the reinforced polymerlayer is commingled with the nonwoven of the laminated facer.
 23. Thecomposite material of claim 22, wherein the polymer film is a polyesterfilm.
 24. The composite material of claim 22, wherein the polymer filmis a polyethylene terephthalate film.
 25. The composite material ofclaim 22, wherein the polymer fibers comprise polyester.
 26. Thecomposite material of claim 22, wherein the polymer polyethyleneterephthalate.
 27. The composite material of claim 22, wherein thepolymer film is selected from the group consisting of polyethylene,polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate,acrylonitrile butadiene styrene, polyvinyl fluoride, polyester,polyurethane, polypropylene, polyethylene terephthalate, polyurea,polyvinyl chloride, EMA or EVA.
 28. The composite material of claim 22,wherein the polymer fibers are selected from the group consisting ofpolyethylene, polyvinylidene fluoride, poly(methyl methacrylate),polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride,polyester, polyurethane, polypropylene, polyethylene terephthalate,polyurea, polyvinyl chloride, EMA, or EVA.
 29. The material of claim 22,further comprising: a layer selected from the group consisting of ametal layer, an ink layer, a polymer layer deposited on at least onesurface of the laminate.
 30. The laminate of claim 21, wherein thepolyester film has a thickness of 0.5-3.0 MIL and the nonwoven has adensity of 17-50 GSM.
 31. A laminate material comprising: a polyesterfilm having a thickness of 0.5-2 mil, a bonded fiber web having adensity of 17-100 GSM and including 20% PET fibers and 80% PETbicomponent fibers cohesively bonded directly to the polyester film,such that portions of the fibers are bonded to the polyester film andportions of the fibers are free from the polyester film; and